Method of producing preformed combination upholstery and insulator padding



June 9, 1959 r. R. UNSWORTH 2,890,146

v METHOD OF PRODUOINO PREFORMEO COMBINATION UPHOLSTERY AND INSULTOR-PADDING 2 sheds-sheet 1 Filed Sept..` 21, 1955 Fig. 2.`

Raymond VR. Unsworth ATTORNEYS uR. R.-UNSWORTH METHOD OF PRODUCING PREFORMED COMBINATION June 9, 1959 UPHOLSTERY AND INSULATOR PADDING 2 'Sheets-Sheet 2 Filed Sept. 21, 1955 QN Mm. mmm O O VM QQN O INVENTOR.

Raymond R. Unsworth ATTORNEYS United States Patent O Y 2,890,146 j y 1- METHOD oF PRoDUcmGPRErom/mn CoM- BINATIoN UPHOLSTERY AND INSULAToR PApDlNG Queenv City'Tulatex-Corporatiom Burlington, Vt., a corporation of Vermont w kApplication. September 21, 1955, Serial No. 535,565 5 Claims. (Cl. 154-101) The present invention relates .to a novel combination upholstery andI insulator padding material for use in mattresses, ,:chairs, furniture and all other cushioning and seatings to be used in conjunction with spring-supporting elements, such as springs of the coil or zigzag type.

`The use -of upholstery padding in furniture is well known. Very briefiy, upholstery padding is that type of padding having an inherent springless or resilience to provide cushioning comfort and the sensation of soft support. Likewise, the use of insulator padding is well known. The function of insulator padding is to insulate or block the feeling of the spring-supporting elements of an article ofl furniture. Such padding accomplishes the desired blockage by distributing weight over the structure of the spring uniformly to the cushioning (upholstery) padding on lthe side of use. When properly constructed and utif lized, the spring section covered with a proper insulator padding provides uniform support yoverthe whole area of thev cushioning, seating or mattress surface. The upholstery padding provides the comfort and softness over this support. k

- My invention. relates to a novel padding having one portion which affords an upholstery or cushioning effect, with the remaining portion providing an insulating effect.

Objects and advantages of the invention will be set forth in part hereinafter and in part will be obvious here-v from, ormay be learned by practice with the invention, the same being realized and attained by means of the steps, compositions, combinations and improvements pointed out in the appended claims. y

The invention consists in the novel steps, processes, constructions, combinations, and improvements herein shown and described.

An object of my invention is to provide a novel padding which affords cushioning comfort and the sensation o f soft support andwat.A thesame time functions to block the feeling of lspringsupporting elements.l

lA further object of my invention is to provide a preformed, integral combination insulator and upholstery padding which is inexpensive and durable, and which may be produced by the use of conventional apparatus.

AAnother object of my invention is to provide a prefabricated, integralv combination pad, preformed to required dimensions, which can be secured to spring-supporting elementskof the article to be upholstered by a single simple fastening operation, such as clamping,` gluing, hogringing, sewing,` or the like.

Another object of my invention is to provide, through the use of the insulator portion of -a combination insulator and upholstery pad, a smooth, lfirm, consistent surface tov-which the upholstery fabric may be applied either d irectly or with a minimum of cotton or cellulose batting.

vAnother-object of `my invention is to provide a novel method for producing a padding having the desired qualities stated in the foregoing objects.

Ii have, found that the foregoing objects are realized by they utilizaiton in a novel manner of curled fibrous ma-- terial of synthetic, animal, vegetable or mineral origin 2,890,146 Patented June 9, 1959 ICC . r2 in conjunction lwith uncurled fibrous material. of synthetic, animal, vegetable or mineral` origin to form'an integral combination upholstery and insulator padding.

More particularly, my novel padding is formed by distributing curled and uncurled bersseparately on a horizontally moving support,such as a moving conveyor belt kaymnd, R Unworth Burlington; .Vt signo-l.- to to build a continuous batt, comprising a layer of curled fibers and a layer .of uncurled fibers and applying av bond,- ing agent to bind the fibers together. The bonded batt or composite layer (layer of curled fibers and layer of uncurled fibers) is then pre-dryed, sized, dehydrated, cured and cut to the desired dimensions by shearing, slitting,

dinking or die-pressing, etc., packed and shipped.

` The portion of my novel material comprising the bonded curled fibers provides the desired cushioning com fort and sensation of soft support, while the remaining portion comprising the bonded uncurled fibers affords the desired insulator action. k

It should bel realized that vvarious modifications may be used in carrying out my invention. For example, the

uncurled fibrous material may be deposited onto the con- Veyor belt before or after the curled material. If the uncurled material is deposited first, the insulator portion is the bottom portion of the initial batt. If the uncurled material is deposited last, the insulator portion is the top portion of the initial batt. The uncurled material is more readily compressible than the curled fibrous material, and,

- resilient spring padding.

' sprayed ,with the bonding V.agent prior'to kthe additiongof` bonded together.

, Also, the sequence of operations with respectto the bonding of the iibers'may be varied. For example, if the uncurlediibersgare depositdfirst' on the conveyor belt,

the layer of unfurled bers formed may or may not be curledfbrous material. Inlike manner, if so desired, the insulator materialvmay be rolled or compressed prior to depositing the curled material 'onthe conveyor. Also, the uncurled materialmay be rinterlaced or punched on a needleloom prior todepositing the curled material.

Regardless of the particular method of applyingy the bonding agent employed, the important thingis that the final layer comprise an integral composite of a layer of uncurled fibrous material bonded together, rsaid layer in turn vbeing bonded to av layer of curled fibrous material lAny suitable curled and uncurled fibers may be used in carrying outlmy invention. Generaly, `the uncurled fibers forming the insulatorportin of my padding are finer and less resilient than the 'curled fibers forming` the, upholstery portion of the padding. Examples of typical curled fibers l ca ttle hair;l mineral fibers such as steel wool or glass wool;

" and vegetable fibers such as coir, cocoa, bristle, omat,

crin vegetal,`Spanish moss, excelsior and the like.

Typical Auncurled fibers, which include sisal tows, hene'quen, tula, pita, palma, and bagasse fibers.

Anyfsuitable lvegetablefor animal adhesive'gum resin orthe like, that will bond the uncurled and curled fibersv togethenmay be used. Examples of suitable bonding agents are vulcanizable natural rubber latex, neoprene,A

G.R.S. andfotherwsynthetic or plastic emulsions; Of course, the quantity AOfi-bonding agent used will vary depending` on the quantity of fibers to be bonded together. Usually, the bonding agentlvaries in an amount from 1A to l part per part of bers. A

Conventional apparatus, utilized -in va novel manner,

maybe used in carrying out my process. For example,

any traveling 4surface suitable for receiving a layer of curled and a layer of uncurled bers may be used, such as the heretofore known conveyors, belts or aprons presently used in forming upholstery paddings.- In like manner, any suitable ber distributing apparatus that will distribute the curled and uncurled bers to form a composite layer may be used, such as a distributor, a spreader, a lapper ofthe camel-back type or horizontal type, etc. Also, any suitable means for applying the bonding agent to the layersof curled and uncurled bers -may be-used, such as a doctor knife, roll coating, dipping, spraying, etc. .Also', any conventional? compressing apparatus for compressing the bonded bers, such as pressure rolls, may

This invention (in a preferred form) is illustrated in the drawings and hereinafter more fully described.

v Figure l is a top plan view, more or less diagrammatic,

of vapparatus utilizing three lappers :for-use in carrying 55 out the continuous method of my invention.

Figure-2 is an elevational view of thedevice of Figure l as seen along either of the lines-2 2 of Figure l.l

Figure 3 is a side elevational -view looking towards the spraying-and drying section of the-apparatus, as indicated 12a, 12b-corresponding camel-back lappers, each of the foregoing individual pieces of equipment being of conventional design which are known to those in the field inthe manufacture of,Y mattress and upholstery bedding. I Each ofthe feedersl', 10a, 10b, is providedv with'corresponding hoppers 13, 13a land 13b'. In theparticular embodiment shows, bers 14 are uncurled bers, and 14a' and'14b' are curled bers. i Itshould'V be understood that the character of the bers'may be varied, depending upon the desred'density or type of padding produced.

` The bers 14, 14a and v14b are drawn through a mechanism of'their respective'feeders 10,10a and 10b, and automatically measured weights vor volumes of the bers are periodically dropped therefrom Vonto traveling aprons 1'5, 15a and-15b, respectively.

:In the garnets 11,11a,111b, the bers 14, 14a and 14h, respectively, are picked, or carded, and dropped onto upwardly traveling conveyors 16, 16a and 16b respectively.`

These conveyors 16,1611 and 16b each constitutes a part of the camel-back lappers '12 '12d and 12b', respectively. Each of the lappers 12, '12a' and '12b includes an oscillatable, downwardly-inclined lapper conveyor 17,` 17a, 17b.V 'The layers of bers 18,' 18a 'andlSb which are carried up by conveyors 16, 16a, 16b, respectively, travel downwardly on conveyors 17, 17a` and 17b, respectively, and are depositedupon the conveyor'19.

vEach of the conveyors 17, 17a and 17b is provided with an oscillatory movement so as to lap the entire width of the conveyor belt. In the particular embodiment shown, as conveyor beltvmoves forward, curled bers from conveyor 17b are deposited over the entire fwidth of the'y conveyor belt to form a ljayer 2017. .As the beltmov'es forwardadditional curledbers are depositedk over the entire 1tyer-20b on lconveyor 17a to form a'thicker layer '20a ofcurle'd fibers.V As the belt moves-further, uncurled bers are deposited by conveyor 17 over the entire width from lc'i;r'1v='.yor,"17b to forma thicker composite layer 20. A short, upwardly-inclined conveyor 21 carries the composite layer'20 to spraying apparatus, indicated generally by the' reference character S, which may suitably comprise a lower suction chamberZZ and an upper spray head 23. A liquid bondingcomposition24 is sprayed onto'the4 moving layer 20 and is drawn by sutQll 'thlfough the batt to thoroughly .impregnate and coat the `curled bers thereof. The individual curled bers are thus uniformly coated with the bonding composition. At the same time, the layer 20 is somewhat compacted by the action of the suction andthe liquid 4bonding composition.

Beyond the spraying apparatus S a conveyor 25 picks up the composite layer,.20, and conveys it into dryer D. The ydryer D comprises a chamber, in which Varemounted three horizontally disposed conveyors 29,'29a'-and 29h, superimposed one above the, other. A reversing roll 31 is positionedvat the delivery- Yend of the drierbetiv'een the lowermost pass 29 and the intermediate pass,29a.-z.-A secondreversiug roll 32 is positioned at the intake Aend of the dryer between the intermediate pass' 29a and 'the upper pass 29b.l Adjustablyv spaced compressing rolls are arranged in a plurality of sets, such as the set 33 associated with the upper run of the conveyor 29 and set 34 associated with the upper run of theconveyor 29a. Blowers 3S `are positioned alongthe back side of the drier for deliverin'gheated air into the drying chamber.

A second spraying apparatus, indicated `generally'by the reference character S', may be positionedbetween the reversing roll 31l and the end of the intermediate conveyor 29a; When passing through the spray apparatus S", the reverse side of the lcomposite layer 20 is sprayed with'a bonding composition to thoroughly impregnateandecoat the uncurled bers thereof and part of the curled bers.

Affter leaving the spraying apparatus S,'the composite web passes over the lowermost conveyor 29, `and is subjected to a drying temperature in the neighborhood of 150 to 180 F. After the composite web has been partially dried, it passes between the set of'rollers 33, which are spaced to compress the layer into a battB of approximately the desired thickness. On compression, the layer 20 forms a layer of uniform thickness.

Y At the spraying apparatus S', the other sidel of layer 20 is sprayed with a vulcanizablerubber latex so as to i insure a uniform coating of the rubber latex over the adequate.

. portion. Advantageously,

ber. It will be understood, however,- that if the batt is relatively thin, orif only a light coating ofrubber latex` is desired, the spray apparatus S may not be used.` Also, while sprayingv has'been found to-be most suitable, ,other means of applying a bonding agent to the brous batt may be employed, such as an immersion tank 'or the like.

' During the passage of the laminated web throughthedrier on the conveyor 29a, itagain passes between a set of sizing rolls 34 while in a partially dried condition in order'to insure the desired'uniform thickness of the finished batt. For some combinations 'of brous materials and bonding agent, only one set of compression rolls'located in the sequence at position 34 has proven In the nal pass through the drier, vover the uppermost conveyor 29h, the pre-dryed composite batt is subjected to suiciently high temperatures to; effect a vulcanization, or cure, of the rubber latex, say in the neighborhood of 225 to 300 F.

The finished batt (Fig. 5) comprises a brous layer 40of loosely associated intermingledbers, theupper portion 41 of which is uncurledbers and the lower portion 42 of which is curled bers, having a coating of a bonding composition, such as vulcanized rubber, over the surfaces thereof, that serves tov hold the bers together. The lower portion 42 possesses aggreater res1liency than the' rupper portion y41 and serves as an upholstery support. The ner, .less resilient, uncurled bers forming upper portion 41 are more readily compressible than the curled bers forming'portion 42; and consequently in sizing the batt' for thickness, the uncurled bers compress into a thinner, harder portion than that formed by the curled bers to provide an effective insulator the insulator or uncurled bers may be softened by wetting or steaming or compacting by rollers so as to approximate a single plane. Accordillgpg the curled bers continue to provide a thicker,

uier batt possessing a greater amount of resilience than the uncurled portion.

It should be understood that various modications may be made of the above-described specic embodiment. For example, instead of distributing curled bers by means of lappers 17b and 17a and uncurled bers by means of lapper 17, uncurled fibers may be distributed by means of end lappers 17b and 17 and curled bers by means of middle lapper 17a, resulting in a combination pad comprising a center upholstery portion of curled bers sandwiched between insulator portions of uncurled bers. If so desired, in place of the three lappers shown in the preferred embodiment, two lappers may be used, one for distributing curled bers and one for distributing the uncurled bers.

My novel method of producing an integral combination upholstery and insulator padding results in a saving in production time, equipment and materials, as compared with the production of an upholstery pad and insulator pad separately. Advantageously, my novel padding may readily be attached to spring-supporting elements of an article of furniture to provide an insulator at its bottom portion and an upholstery portion at its top portion. In short, I have produced a novel combination upholstery and insulator padding for use over springsupporting elements of furniture which provides an eicient, tough, inexpensive, easy to produce, long-lived, durable and comfortable seating or bedding.

The invention in its broader aspects is not limited to the specic steps, compositions, combinations and improvements described, but departures may be made therefrom Within the scope of the accompanying claims without departing from the principles of the invention, and without sacricing its chief advantages.

What is claimed is:

1. A method for the manufacture of an integral combination insulator and upholstery padding, comprising distributing separately loosely intermingled uncurled bers and loosely intermingled curled bers on a generally horizontal traveling surface to provide a layer of uncurled bers and a layer of curled bers, applying a 6 bonding agent to said bers to bond the bers together to form an integral nal layer.

2. The method of claim 1, wherein the uncurled bers are ner and less resilient than the curled bers, and wherein the nal layer is compressed for sizing, the uncurled bers compressing to a higher degree than the curled bers to provide a stiffer, denser portion than the portion formed by the curled bers.

3. The method of claim 1, wherein the uncurled bers are softened so as to approximate a single plane.

4. A method for the manufacture of an integral combination insulator and upholstery padding, comprising distributing loosely intermingled uncurled bers and loosely intermingled curled bers in layers on a horizontal surface to provide a layer of uncurled bers and a layer of curled bers with an interface of intermingled uncurled and curled bers, and applying a bonding agent to said bers to bond the bers together to form an integral nal layer,

5. The method of claim 4, wherein the uncurled bers are ner and less resilient than the curled bers, and wherein the nal layer is compressed for sizing, the uncurled bers compressing to a higher degree than the curled bers to provide a stiffer, denser portion than the portion formed by the curled bers.

References Cited in the le of this patent UNITED STATES PATENTS 2,341,130 Unsworth Feb. 8, 1944 2,385,870 Lashar et al. Oct. 2, 1945 2,397,936 Glidden et al. Apr. 9, 1946 2,565,941 Barnard Aug. 28, 1951 2,571,334 Browne Oct. 16, 1951 2,574,849 Talalay Nov. 13, 1951 2,580,202 Talalay et al Dec. 25, 1951 2,624,079 Duvall Jan. 6, 1953 2,662,044 Morrison et al. Dec. 8, 1953 2,742,951 Marc Apr. 24, 1956 FOREIGN PATENTS 141,085 Australia May 7, 1951 

1. A METHOD FOR THE MANUFACTURE OF AN INTEGAL COMBINATION INSULATOR AND UPHOLSTERY PADDING, COMPRISING DISTRIBUTING SEPARATELY LOOSELY INTERMINGLED UNCURLED FIBERS AND LOOSELY INTERMINGLED CURLED FIBERS O A GENERALLY HORIZONTAL TRAVELING SURFACE TO PROVIDE A LAYER OF UNCULRED FIBERS AND A LAYER OF CURLEDFIBERS, APPLYING A BONDING AGENT TO SAID FIBERS TO BOND THE FIBERS TOGETHER TO FORM AN INTEGRAL FINAL LAYER. 